Semiconductor structure and fabricating method thereof

ABSTRACT

A semiconductor structure includes a substrate, a hole which includes a top hole and a bottom hole in communication with each other in the substrate, and a filler in the top hole and the bottom hole, wherein the top hole tapers toward the bottom hole, and a side surface of the top hole and a side surface of the bottom hole form an obtuse angle.

PRIORITY CLAIM AND CROSS-REFERENCE

This application claims priority of U.S. provisional application Ser. No. 62/429,100, which was filed on Dec. 2, 2016, the entire disclosure of which is incorporated herein by reference.

BACKGROUND

To achieve increased density and performance of integrated circuits (ICs), the characteristic size of features on those circuits is decreased. Fabrication of IC devices introduces new challenges in process development and control.

During fabricating features, such as through-silicon vias (TSVs) and trench capacitors, the fabricating process may include forming trenches or holes in a substrate and then filling materials in the trenches or holes. Additional metal lines and/or metal pads are then formed over and electrically coupled to the TSVs, for example, using damascene processes. TSVs may also be formed after all metal layers and passivation layers are formed, and may be formed from the front side or the back side of the respective wafers/chips, which approaches are referred to as via-last approaches.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is noted that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIG. 1 is a flowchart of a method of fabricating a semiconductor structure in accordance with some embodiments of the instant disclosure.

FIGS. 2A to 2G are cross-sectional views of a method for manufacturing a semiconductor structure at various stages in accordance with some embodiments of the instant disclosure.

FIG. 3 is a flowchart of a method of fabricating a semiconductor structure in accordance with some embodiments of the instant disclosure.

FIGS. 4A to 4G are cross-sectional views of a method for manufacturing a semiconductor structure at various stages in accordance with some embodiments of the instant disclosure.

FIG. 5 is a flowchart of a method of fabricating a semiconductor structure in accordance with some embodiments of the instant disclosure.

FIGS. 6A to 6I are cross-sectional views of a method for manufacturing a semiconductor structure at various stages in accordance with some embodiments of the instant disclosure.

FIG. 7 is a top view of the substrate shown in FIG. 6A.

FIG. 8 is a flowchart of a method of fabricating a semiconductor structure in accordance with some embodiments of the instant disclosure.

FIGS. 9A to 9F are cross-sectional views of a method for manufacturing a semiconductor structure at various stages in accordance with some embodiments of the instant disclosure.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

Other features and processes may also be included. For example, testing structures may be included to aid in the verification testing of the 3D packaging or 3DIC devices. The testing structures may include, for example, test pads formed in a redistribution layer or on a substrate that allows the testing of the 3D packaging or 3DIC, the use of probes and/or probe cards, and the like. The verification testing may be performed on intermediate structures as well as the final structure. Additionally, the structures and methods disclosed herein may be used in conjunction with testing methodologies that incorporate intermediate verification of known good dies to increase the yield and decrease costs.

FIG. 1 is a flowchart of a method 100 of fabricating a semiconductor structure in accordance with some exemplary embodiments of the instant disclosure. Operation 101 of the method is forming a top hole in a substrate. The method continues with operation 103 in which a bottom hole extending from a bottom of the top hole into the substrate is formed to form a funnel-shaped blind hole. Operation 105, a dielectric material is formed over the substrate and in the funnel-shaped blind hole. The method continues with operation 107 in which at least one conductive material is formed over the dielectric material and in the funnel-shaped blind hole. The method continues with operation 109 in which a portion of the at least one conductive material that is over the dielectric material is removed. The method continues with operation 111 in which a metallic line is formed in the dielectric material. Operation 113, the substrate is thinned from the bottom surface of the substrate. It is understood that FIG. 1 has been simplified for a good understanding of the concepts of the instant disclosure. Accordingly, it should be noted that additional processes may be provided before, during, and after the methods of FIG. 1, and that some other processes may only be briefly described herein.

FIGS. 2A to 2G are cross-sectional views of a method for manufacturing a semiconductor structure 200 at various stages in accordance with some embodiments of the instant disclosure.

Reference is made to FIGS. 2A and 2B. A top hole H₁₁ is formed in a substrate 213 (the operation 101 of FIG. 1). As shown in FIG. 2A, the substrate 213 includes a semiconductor substrate 201, at least one isolation structure, e.g., an isolation structure 203, at least one transistor, e.g., a transistor 205, a dielectric layer 207, at least one contact plug, e.g., a contact plug 209, and an etch stop layer 211.

In some embodiments, the semiconductor substrate 201 may include an elementary semiconductor including silicon or germanium in a crystalline, a polycrystalline, or an amorphous structure; a compound semiconductor including silicon carbide, gallium arsenide, gallium phosphide, indium phosphide, indium arsenide, and/or indium antimonide; an alloy semiconductor including SiGe, GaAsP, AlInAs, AlGaAs, GaInAs, GaInP, and/or GaInAsP; any other suitable material; or combinations thereof. In some embodiments, the alloy semiconductor substrate may have a gradient SiGe feature in which the Si and Ge composition change from one ratio at one location to another ratio at another location of the gradient SiGe feature. In some other embodiments, the alloy SiGe is formed over a silicon substrate. In still some other embodiments, a SiGe substrate is strained. Furthermore, the semiconductor substrate may be a semiconductor on insulator, such as a silicon on insulator (SOI), or a thin film transistor (TFT). In some examples, the semiconductor substrate may include a doped epi layer or a buried layer. In other examples, the compound semiconductor substrate may have a multilayer structure, or the substrate may include a multilayer compound semiconductor structure.

Still referring to FIG. 2A, the isolation structure 203 is formed in the semiconductor substrate 201. In some embodiments, the isolation structure 203 can be a shallow trench isolation (STI) structure, a local oxidation of silicon (LOCOS) structure, and/or combinations thereof. The isolation structure 203 can be made of at least one material, such as silicon oxide, silicon nitride, silicon oxynitride, other dielectric materials, and/or combinations thereof. The transistor 205 is formed over the semiconductor substrate 201. The dielectric layer 207 is formed over the semiconductor substrate 201, the isolation structure 203, and the transistor 205. In some embodiments, the dielectric layer 207 can be made of at least one material, such as silicon oxide, e.g., undoped silicate glass (USG), boron-doped silicate glass (BSG), phosphor-doped silicate glass (PSG), boron-phosphor-doped silicate glass (BPSG), or the like, silicon oxy-nitride, silicon nitride, a low-k material, and/or any combinations thereof. In some embodiments, the dielectric layer 207 is referred to as an inter-layer dielectric (ILD) layer. In some embodiments, a multiple-layer dielectric structure can be formed over the semiconductor substrate 201. The contact plug 209 is formed in the dielectric layer 207 to electrically connect with the transistor 205. The etch stop layer 211 is formed over the dielectric layer 207. In some embodiments, the etch-stop layer 211 can be made of a material including at least one of, for example, nitride, oxynitride, carbide, oxycarbide, other dielectric materials having an etch selectivity substantially different from that of the dielectric layer 207, and/or combinations thereof. It is noted that though merely showing a single etch-stop layer 211 in FIG. 1, the scope of this application is not limited thereto. In some embodiments, a multiple-layer etch-stop structure can be formed over the dielectric layer 207.

As shown in FIG. 2B, a patterned mask layer 215 which has an opening 217 is formed on a top surface S₁₁ of the substrate 213. An etching process, e.g., an isotropic etching process, by using the patterned mask layer 215 as an etch mask, can remove a portion of the substrate 213 to form the top hole H₁₁ which is a blind hole. In some embodiments, the isotropic etching process is a wet etching process. In FIG. 2B, portions of the etch stop layer 211, the dielectric layer 207, and the isolation structure 203 are removed to form the top hole H₁₁. However, it is noted that the scope of this application is not limited thereto. The height of the top hole H₁₁ can be adjusted.

More specifically, the top hole H₁₁ has a width decreases from top to bottom. In other words, the top hole H₁₁ tapers from the top surface S₁₁ of the substrate 213 toward the bottom surface S₁₁ of the substrate 213. In some embodiments, the top hole H₁₁ is formed by etching the substrate 213 through the opening 217 by an isotropic etching process. Because the isotropic etching etches horizontally as well as vertically into the top surface S₁₁ of the substrate 213, as shown in FIG. 2B, the top hole H₁₁ is substantially bowl-shaped. In other words, the top hole H₁₁ is concave. Accordingly, an inner surface 219 of the top hole H₁₁ is concave, and a side surface 219 a of the inner surface 219 of the top hole H₁₁ is also concave. It is noted that the scope of this application is not limited thereto. The shape of the top hole H₁₁ can be adjusted by using another etching process. In some other embodiments, the cross section of the top hole H₁₁ is substantially inverted trapezoidal, and the side surface of the top hole H₁₁ is substantially straight. In some other embodiments, the top hole H₁₁ has a convex side surface. The term “substantially” as used herein may be applied to modify any quantitative representation which could permissibly vary without resulting in a change in the basic function to which it is related.

Reference is made to FIG. 2C. A bottom hole H₁₂ extending from a bottom of the top hole H₁₁ into the substrate 213 is formed to form a funnel-shaped blind hole H₁ (the operation 103 of FIG. 1). In other words, forming the bottom hole H₁₂ stops before the bottom hole H₁₂ penetrates through the substrate 213. The top hole H₁₁ in communication with the bottom hole H₁₂ is referred to as a top hole H_(11a). An etching process, e.g., an anisotropic etching process, by using the patterned mask layer 215 as an etch mask, can remove a portion of the substrate 213 to form the bottom hole H₁₂. In FIG. 2C, portions of the isolation structure 203 and the semiconductor substrate 201 are removed to form the bottom hole H₁₂. It is noted that the scope of this application is not limited thereto. The height of the bottom hole H₁₂ can be adjusted. In some embodiments, the anisotropic etching process is dry etching process, e.g., deep reactive-ion etching (DRIE), which is used to form deep penetration, steep-sided holes and trenches in wafers/substrates, typically with high aspect ratios. For example, DRIE is Bosch etching or cryogenic etching. After forming the funnel-shaped blind hole H₁, the patterned mask layer 215 is removed.

In some embodiments, the bottom hole H₁₂ is formed by etching the substrate 213 through the opening 217 by an anisotropic etching process. Because the anisotropic etching etches in a single direction into the surface of the substrate 213, as shown in FIG. 2C, the bottom hole H₁₂ is a substantially straight hole. In some embodiments, a side surface 221 a of an inner surface 221 of the bottom hole H₁₂ is substantially straight. In some embodiments, the side surface 221 a of the inner surface 221 of the bottom hole H₁₂ substantially aligns with the side surface 217 a of the opening 217 of the patterned mask layer 215. It is noted that the side surface 219 a of the top hole H_(11a) and the side surface 221 a of the bottom hole H₁₂ form an obtuse angle θ₁ as shown in FIG. 2C.

Still referring to FIG. 2C, the top hole H_(11a) has a first top width w₁₁ and a first height h₁₁. In some embodiments, the ratio of the first height h₁₁ to the first top width w₁₁ is about 0.5 to about 2. In some embodiments, the first top width w₁₁ ranges from about 0.2 to about 15 μm. In some embodiments, the first height h₁₁ ranges from about 0.1 to about 10 μm. The bottom hole H₁₂ has a second top width w₁₂ and a second height h₁₂. The second height h₁₂ is greater than the first height h₁₁. In some embodiments, the ratio of the second height h₁₂ to the second top width w₁₂ is about 1 to about 20. In some embodiments, the second top width w₁₂ ranges from about 0.1 to about 10 μm. In some embodiments, the second height h₁₂ ranges from about 1 to about 200 μm.

As shown in FIG. 2C, the first top width w₁₁ of the top hole H_(11a) is greater than the second top width w₁₂ of the bottom hole H₁₂, and thus the upper portion (i.e., the top hole H_(11a)) of the funnel-shaped blind hole H₁ is wider than the lower portion (i.e., the bottom hole H₁₂) of the funnel-shaped blind hole H₁. Such shape of the funnel-shaped blind hole H₁ is good for filling material, such as conductive material and dielectric material, into the funnel-shaped blind hole H₁ without causing seams or voids in the material. During the filling process, the material can be deposited on the inner surface of the funnel-shaped blind hole H₁ to fill the funnel-shaped blind hole H₁, such that the material disposed in the funnel-shaped blind hole H₁ has a smooth and planar top surface.

Attention is now invited to FIG. 2D. A dielectric material 223 is formed over the substrate 213 and in the funnel-shaped blind hole H₁, and at least one conductive material 225 is formed over the dielectric material 223 and in the funnel-shaped blind hole H₁ (the operation 105 and 107 of FIG. 1). In some embodiments, the dielectric material 223 and the at least one conductive material 225 are referred as a filler. Accordingly, the operation 105 and 107 also can be regarded as forming a filler in the top hole H_(11a) and the bottom hole H₁₂. As shown in FIG. 2D, the dielectric material 223 continuously extends over the substrate 213 and into the funnel-shaped blind hole H₁. More specifically, the dielectric material 223 is conformally disposed in the top hole H_(11a) and the bottom hole H₁₂, and in contact with the inner surface 219 of the top hole H_(11a) and the inner surface 221 of the bottom hole H₁₂. Similarly, the at least one conductive material 225 conformally covers the dielectric material 223. In some embodiments, the at least one conductive material 225 includes a barrier metallic material 225 a and a metallic material 225 b as shown in FIG. 2D. The barrier metallic material 225 a can be formed by, for example, chemical vapor deposition (CVD), physical vapor deposition (PVD), atomic layer deposition (ALD), and/or other suitable processes. The metallic material 225 b can be formed by, for example, CVD, electroplating, and/or other suitable processes to fill the metallic material 225 b in the funnel-shaped blind hole H₁.

Because the top hole H_(11a) is wider than the bottom hole H₁₂, the funnel-shaped blind hole H₁ have a good filling performance with the dielectric material 223 and the at least one conductive material 225. Moreover, there can be no seam or void in the dielectric material 223 and the at least one conductive material 225, and in some embodiments, the at least one conductive material 225 has a substantially planar top surface. In other words, the dielectric material 223 and the at least one conductive material 225 can be seam-free and void-free.

Please refer to FIG. 2E. A portion of the at least one conductive material 225 that is over the dielectric material 223 is removed. (the operation 109 of FIG. 1). In some embodiments, the at least one conductive material 225 is removed by a chemical mechanical polish (CMP) process, a dry etching process, and/or combinations thereof. In some embodiments, a portion of the dielectric material 223 that is under the at least one conductive material 225 and outside the funnel-shaped blind hole H₁ is removed after the removing process. The remaining portion of the dielectric material 223 is referred to as a dielectric material 223 a.

Turning now to FIG. 2F, a metallic line 235 is formed in the dielectric material 223 a (the operation 111 of FIG. 1). In some embodiments, forming the metallic line 235 includes the following operations. A cap layer (not shown) is formed over the dielectric material 223 a and the at least one conductive material 225. The cap layer may be made of at least one material that is similar to or the same as the material of the etch stop layer 211. A patterned mask layer (not shown) is formed on the cap layer. The patterned mask layer has at least one opening that exposes a portion of the cap layer. Portions of the cap layer, the dielectric material 223 a, and the etch stop layer 211 are removed by an etching process to form an opening 233 to expose the contact plug 209, and the patterned mask layer is removed. A barrier metallic material layer and a metallic material layer are formed in the opening 233 and over the remaining cap layer. The remaining cap layer and portions of the barrier metallic material layer and the metallic material layer are removed to expose the dielectric material 223 a and to form the metallic line 235 in the opening 233. In some embodiments, the metallic line 235 includes a barrier metallic material layer 235 a and a metallic material layer 235 b disposed on the barrier metallic material layer 235 a.

Attention is now invited to FIG. 2G. The substrate 213 is thinned from the bottom surface S₁₂ of the substrate 213 to expose the at least one conductive material 225. (the operation 113 of FIG. 1). In FIG. 2G, a portion of the at least one conductive material 225 is also removed. Accordingly, the semiconductor structure 200 is formed. It is noted that, after the operation 113, the shape of the bottom hole H₁₂ is changed, and the shape of the funnel-shaped blind hole H₁ is changed accordingly. The changed bottom hole H₁₂ is referred to as a bottom hole H_(12a) which has a second height h_(12a) shorter than the second height h₁₂ of the bottom hole H₁₂. The changed funnel-shaped blind hole H₁ is referred to as a funnel-shaped through hole H_(1a).

As shown in FIG. 2G, the semiconductor structure 200 includes the substrate 213, the dielectric material 223 a, the at least one conductive material 225, and the metallic line 235. The substrate 213 includes the semiconductor substrate 201, the isolation structure 203, the transistor 205, the dielectric layer 207, the contact plug 209, and the etch stop layer 211. The substrate 213 has the top surface S₁₁ and the bottom surface S₁₂, and has the funnel-shaped through hole H_(1a) therein. The funnel-shaped through hole H_(1a) extends through the substrate 213 between the top surface S₁₁ and the bottom surface S₁₂. The funnel-shaped through hole H_(1a) has the top hole H_(11a) and the bottom hole H_(12a) under the top hole H_(11a). The top hole H_(11a) and the bottom hole H_(12a) are in communication with each other. The side surface 219 a of the top hole H_(11a) and the side surface 221 a of the bottom hole H_(11a) form the obtuse angle θ₁. The top hole H_(11a) has the first top width w₁₁ greater than the second top width w₁₂ of the bottom hole H_(12a). Moreover, the top hole H_(11a) tapers from the top surface S₁₁ toward the bottom hole H_(12a) (or the bottom surface S₁₂). In some embodiments, the side surface 219 a of the top hole H_(11a) is curved. In FIG. 2G, the side surface 219 a of the top hole H_(11a) is concave. In some other embodiments, the side surface of the top hole H_(11a) is convex or substantially straight. The dielectric material 223 a is conformally disposed in the top hole H_(11a) and the bottom hole H_(12a), and in contact with the inner surface 219 of the top hole H_(11a), the inner surface 221 of the bottom hole H_(12a), and the top surface S₁₁ of the substrate 213. The at least one conductive material 225 is disposed on the dielectric material 223 a and in the top hole H_(11a) and the bottom hole H_(12a). In other words, the at least one conductive material 225 penetrating through the substrate 213 is in the funnel-shaped through hole H_(1a), and is surrounded by the dielectric material 223 a. Accordingly, the funnel-shaped through hole H_(1a) is filled with the dielectric material 223 a and the at least one conductive material 225. In some embodiments, the at least one conductive material 225 includes the barrier metallic material 225 a and the metallic material 225 b. In some embodiments, the at least one conductive material 225 is referred to as a through-substrate via (TSV) structure. The transistor 205 is disposed over the semiconductor substrate 201. The metallic line 235 is disposed in the dielectric material 223 a and includes the barrier metallic material layer 235 a and the metallic material layer 235 b. The contact plug 209 is electrically coupled between the transistor 205 and the metallic line 235.

Still referring to FIG. 2G, as previously described, in some embodiments, the dielectric material 223 and the at least one conductive material 225 are referred as a filler. Moreover, the dielectric material 223 a is formed from the dielectric material 223. Therefore, alternatively, the semiconductor structure 200 includes a filler F₁ disposed in the top hole H_(11a) and the bottom hole H_(12a). The filler F₁ includes a top portion T₁ (i.e., the portion of the dielectric material 223 a and the at least one conductive material 225 filled in the top hole H_(11a)) and a bottom portion B₁ (i.e., the portion of the dielectric material 223 a and the at least one conductive material 225 filled in the bottom hole H_(12a)) in contact with the top portion T₁. As shown in FIG. 2G, the top portion T₁ has a convex side surface 237 extending from a top of the top portion T₁ to a top of the bottom portion B₁, and has the first top width w₁₁ greater than the second top width w₁₂ of the bottom portion B₁.

FIG. 3 is a flowchart of a method 300 of fabricating a semiconductor structure in accordance with some exemplary embodiments of the instant disclosure. Operation 301 of the method is introducing a dopant into a substrate to form a doped region. The method continues with operation 303 in which at least one top hole is formed in the doped region. Operation 305, a bottom hole extending from a bottom of the top hole into the doped region is formed to form a funnel-shaped blind hole. The method continues with operation 307 in which a dielectric material is formed over the substrate and in the funnel-shaped blind hole. The method continues with operation 309 in which a first conductive layer is formed over the dielectric material. The method continues with operation 311 in which a dielectric interlayer is formed over the first conductive layer. Operation 313, a second conductive layer is formed over the dielectric interlayer. The method continues with operation 315 in which the dielectric interlayer and the second conductive layer are patterned. Operation 317, the first conductive layer is patterned. In operation 319, an inter-layer dielectric (ILD), contact elements, and metal lines are formed. It is understood that FIG. 3 has been simplified for a good understanding of the concepts of the instant disclosure. Accordingly, it should be noted that additional processes may be provided before, during, and after the methods of FIG. 3, and that some other processes may only be briefly described herein.

FIGS. 4A to 4G are cross-sectional views of a method for manufacturing a semiconductor structure 400 at various stages in accordance with some embodiments of the instant disclosure.

Reference is made to FIG. 4A. A dopant is introduced into a substrate 401 to form a doped region 403 (operation 301 of FIG. 3). The substrate 401 may be made of at least one material that is similar to or the same as the material of the semiconductor substrate 201. The doped region 403 may be an N-type doped region or a P-type doped region. In some embodiments, the doped region 403 is an N-type doped region formed by implanting an N-type dopant into the substrate 401. For instance, phosphor is implanted in the substrate 310 to form the doped region 403. Alternatively, other N-type dopants such as arsenic and antimony may be used in the ion implantation process.

Reference is made to FIG. 4B. At least one top hole H₂₁ is formed in the doped region 403 of the substrate 401 (operation 303 of FIG. 3). More specifically, a patterned mask layer 405 which has at least one opening 407 is formed on the doped region 403. An etching process, e.g., an isotropic etching process, by using the patterned mask layer 405 as an etch mask, can remove at least a portion of the doped region 403 to form the top hole H₂₁. The top hole H₂₁ is a blind hole. In some embodiments, the isotropic etching process is a wet etching process.

The top hole H₂₁ has a width decreases from top to bottom. In other words, the top hole H₂₁ tapers from the top surface S₂₁ of the substrate 401 toward the bottom surface S₂₂ of the substrate 401. In some embodiments, the top hole H₂₁ is formed by etching the doped region 403 of the substrate 401 through the opening 407 by an isotropic etching process. Accordingly, the top hole H₂₁ is substantially bowl-shaped. In other words, the top hole H₂₁ is concave. Accordingly, an inner surface 409 of the top hole H₂₁ is concave, and a side surface 409 a of the inner surface 409 of the top hole H₂₁ is also concave. It is noted that the scope of this application is not limited thereto. The shape of the top hole H₂₁ can be adjusted by using another etching process. In some other embodiments, the cross section of the top hole H₂₁ is substantially inverted trapezoidal, and the side surface of the top hole H₂₁ is substantially straight. In still some other embodiments, the top hole H₂₁ has a convex side surface.

Reference is made to FIG. 4C. A bottom hole H₂₂ extending from a bottom of the top hole H₂₁ into the doped region 403 is formed to form a funnel-shaped blind hole H₂ (operation 305 of FIG. 3). In other words, forming the bottom hole H₂₂ stops before the bottom hole H₂₂ penetrates through the doped region 403 of the substrate 401. The top hole H₂₁ in communication with the bottom hole H₂₂ is referred to as a top hole H_(21a). An etching process, e.g., an anisotropic etching process, by using the patterned mask layer 405 as an etch mask, can remove a portion of the doped region 403 to form the bottom hole H₂₂. In some embodiments, the anisotropic etching process is dry etching process, e.g., deep reactive-ion etching (DRIE). For example, DRIE is Bosch etching or cryogenic etching. After forming the funnel-shaped blind hole H₂, the patterned mask layer 405 is removed.

In some embodiments, the bottom hole H₂₂ is formed by etching the doped region 403 of the substrate 401 through the opening 407 by an anisotropic etching process. Accordingly, the bottom hole H₂₂ is a substantially straight hole. In some embodiments, a side surface 411 a of an inner surface 411 of the bottom hole H₁₂ is substantially straight. In some embodiments, the side surface 411 a of the inner surface 411 of the bottom hole H₂₂ substantially aligns with a side surface 407 a of the opening 407 of the patterned mask layer 405. It is noted that the side surface 409 a of the top hole H_(21a) and the side surface 411 a of the bottom hole H₂₂ form an obtuse angle θ₂ as shown in FIG. 4C.

Still referring to FIG. 4C, the top hole H_(21a) has a first top width w₂₁ and a first height h₂₁. In some embodiments, the ratio of the first height h₂₁ to the first top width w₂₁ is about 0.5 to about 2. In some embodiments, the first top width w₂₁ ranges from about 0.2 to about 15 μm. In some embodiments, the first height h₂₁ ranges from about 0.1 to about 10 μm. The bottom hole H₂₂ has a second top width w₂₂ and a second height h₂₂. The second height h₂₂ is greater than the first height h₂₁. In some embodiments, the ratio of the second height h₂₂ to the second top width w₂₂ is about 1 to about 20. In some embodiments, the second top width w₂₂ ranges from about 0.1 to about 10 μm. In some embodiments, the second height h₂₂ ranges from about 1 to about 200 μm.

As shown in FIG. 4C, the first top width w₂₁ of the top hole H_(21a) is greater than the second top width w₂₂ of the bottom hole H₂₂, and thus the upper portion (i.e., the top hole H_(21a)) of the funnel-shaped blind hole H₂ is wider than the lower portion (i.e., the bottom hole H₂₂) of the funnel-shaped blind hole H₂. Such shape of the funnel-shaped blind hole H₂ is good for filling material, such as conductive material and dielectric material, into the funnel-shaped blind hole H₂ without causing seams or voids in the material. During the filling process, the material can be deposited on the inner surface of the funnel-shaped blind hole H₂ to fill the funnel-shaped blind hole H₂, such that the material disposed in the funnel-shaped blind hole H₂ has a smooth and planar top surface.

Attention is now invited to FIG. 4D. A dielectric material 413 is formed over the substrate 401 and in the funnel-shaped blind hole H₂, a first conductive layer 415 is formed over the dielectric material 413, a dielectric interlayer 417 is formed over the first conductive layer 415, and a second conductive layer 419 is formed over the dielectric interlayer 417 (the operations 307-313 of FIG. 3). In some embodiments, the dielectric material 413, the first conductive layer 415, the dielectric interlayer 417, and the second conductive layer 419 are referred as a filler. Accordingly, the operations 307-313 also can be regarded as forming a filler in the top hole H_(21a) and the bottom hole H₂₂. The dielectric material 413 continuously extends over the substrate 401 and into the funnel-shaped blind hole H₂. More specifically, the dielectric material 413 is conformally disposed in the top hole H_(21a) and the bottom hole H₂₂, and in contact with the inner surface 409 of the top hole H_(21a) and the inner surface 411 of the bottom hole H₂₂. The first conductive layer 415 conformally covers the dielectric material 413, the dielectric interlayer 417 conformally covers the first conductive layer 415, and the second conductive layer 419 conformally covers the dielectric interlayer 417. The funnel-shaped blind hole H₂ is filled with the dielectric material 413, the first conductive layer 415, the dielectric interlayer 417, and the second conductive layer 419.

Because the top hole H_(21a) is wider than the bottom hole H₂₂, the funnel-shaped blind hole H₁ can be filled with the dielectric material 413, the first conductive layer 415, the dielectric interlayer 417, and the second conductive layer 419. Moreover, there is no seam or void in the dielectric material 413, the first conductive layer 415, the dielectric interlayer 417, and the second conductive layer 419. In some embodiments, the second conductive layer 419 has a substantially planar top surface. In other words, the stack including the dielectric material 413, the first conductive layer 415, the dielectric interlayer 417, and the second conductive layer 419 can be seam-free and void-free.

Please refer to FIG. 4E. The dielectric interlayer 417 and the second conductive layer 419 are patterned (the operation 315 of FIG. 3). More specifically, the second conductive layer 419 and the dielectric interlayer 417 therebeneath are patterned to define a top electrode 419 a over the funnel-shaped blind hole H₂ and expose a portion of the first conductive layer 415. For example, a patterned mask layer (not shown) is formed on the second conductive layer 419. A portion of the second conductive layer 419, which is not covered by the patterned mask layer, and a portion of the dielectric interlayer 417 are removed to define the top electrode 419 a. In some embodiments, a dry etching process may be performed to remove the portions of the second conductive layer 419 and the dielectric interlayer 417.

Turning now to FIG. 4F, the first conductive layer 415 is patterned (the operation 317 of FIG. 3). A portion of the first conductive layer 415 is patterned to define a bottom electrode 415 a beneath the top electrode 419 a. The doped region 403, the dielectric material 413, the bottom electrode 415 a, the dielectric interlayer 417 and the top electrode 419 a constitute a capacitor 421. The dielectric material 413 may be selectively patterned. In FIG. 4F, the operation 317 further includes patterning the dielectric material 413 beneath the first conductive layer 415. In some other embodiments, the dielectric material 413 is not patterned (not shown).

Attention is now invited to FIG. 4G. A patterned inter-layer dielectric (ILD) layer 423, contact elements, 427 a, 427 b and 427 c, and metal lines 429 are formed (the operation 319 of FIG. 3). More specifically, an ILD layer (not shown) is formed over the capacitor 421. The ILD layer may be formed by deposition, such as PECVD, LPCVD or APCVD. The ILD layer is patterned to form the patterned inter-layer dielectric 423 which has a plurality of contact windows 425 a, 425 b and 425 c respectively exposing a portion of the doped region 403, a portion of the bottom electrode 415 a and a portion of the top electrode 419 a. A plurality of contact elements 427 a, 427 b and 427 c are respectively formed in the contact windows 425 a, 425 b and 425 c to contact the doped region 403, the bottom electrode 415 a and the top electrode 419 a, as shown in FIG. 4G. In some embodiments, the contact elements 427 a, 427 b and 427 c are made of tungsten and formed by deposition. The metal lines 429 may be formed on the top surface of the patterned ILD layer 423 to respectively contact the contact elements 427 a, 427 b and 427 c. Accordingly, the semiconductor structure 400 is formed.

As shown in FIG. 4G, the semiconductor structure 400 includes the substrate 401, the dielectric material 413, the bottom electrode 415 a, the dielectric interlayer 417, the top electrode 419 a, the patterned inter-layer dielectric 423, the contact elements 427 a, 427 b and 427 c, and the metal lines 429. The substrate 401 includes the doped region 403. The doped region 403 extends from the top surface S₂₁ of the substrate 401 toward the bottom surface S₂₂ of the substrate 401, and has a top surface and a bottom surface. The doped region 403 of the substrate 401 has the funnel-shaped blind hole H₂ therein. The funnel-shaped blind hole H₂ is disposed in the doped region 403, and extends from the top surface of the doped region 403 toward the bottom surface of the doped region 403. The funnel-shaped blind hole H₂ includes the top hole H_(21a) and the bottom hole H₂₂ in communication with each other. The side surface 409 a of the top hole H_(21a) and the side surface 411 a of the bottom hole H₂₂ form the obtuse angle θ₂. The top hole H_(21a) has the first top width w₂₁ greater than the second top width w₂₂ of the bottom hole H₂₂. Moreover, the top hole H_(21a) tapers from the top surface of the doped region 403 toward the bottom hole H₂₂ (or the bottom surface of the doped region 403). In some embodiments, the side surface 409 a of the top hole H_(21a) is curved. In FIG. 4G, the side surface 409 a of the top hole H_(21a) is concave. In some other embodiments, the side surface of the top hole H_(21a) is convex or substantially straight. The dielectric material 413 is conformally disposed in the top hole H_(21a) and the bottom hole H₂₂, and covers the side surface 409 a of the top hole H_(21a), the inner surface 411 of the bottom hole H₂₂, and the top surface of the doped region 403. The bottom electrode 415 a is conformally disposed on the dielectric material 413 and at least partially in the top hole H_(21a) and the bottom hole H₂₂. The dielectric interlayer 417 is conformally disposed on the bottom electrode 415 a and at least partially in the top hole H_(21a) and the bottom hole H₂₂. The top electrode 419 a is disposed on the dielectric interlayer 417. The funnel-shaped blind hole H₂ is filled with the dielectric material 413, the bottom electrode 415 a, the dielectric interlayer 417, and the top electrode 419 a. The patterned inter-layer dielectric 423 covers the capacitor 421. The contact elements 427 a, 427 b and 427 c are embedded in the patterned inter-layer dielectric 423 and respectively contact the doped region 403, the bottom electrode 415 a, and the top electrode 419 a. More specifically, the patterned inter-layer dielectric 423 has the contact windows 425 a, 425 b and 425 c to expose a portion of the doped region 403, a portion of the bottom electrode 415 a, and a portion of the top electrode 419 a, and the contact elements 427 a, 427 b and 427 c are respectively disposed in the contact windows 425 a, 425 b and 425 c. The metal lines 429 are disposed on the patterned inter-layer dielectric 423 and respectively contact the contact elements 427 a, 427 b and 427 c. The contact elements 427 a, 427 b and 427 c are acted as electrical connections between the metal lines 429 and the doped region 403, the bottom electrode 415 a and the top electrode 419 a.

Still referring to FIG. 4G, as previously described, in some embodiments, the dielectric material 413, the first conductive layer 415, the dielectric interlayer 417, and the second conductive layer 419 are referred as a filler. Moreover, the bottom electrode 415 a is formed by patterning the first conductive layer 415, and the top electrode 419 a is formed by patterning the second conductive layer 419. Therefore, alternatively, the semiconductor structure 400 includes a filler F₂ disposed in the top hole H_(21a) and the bottom hole H₂₂. The filler F₂ includes a top portion T₂ (i.e., the portion of the dielectric material 413, the bottom electrode 415 a, the dielectric interlayer 417, and the top electrode 419 a filled in the top hole H_(21a)) and a bottom portion B₂ (i.e., the portion of the dielectric material 413, the bottom electrode 415 a, the dielectric interlayer 417, and the top electrode 419 a filled in the bottom hole H₂₂) in contact with the top portion T₂. As shown in FIG. 4G, the top portion T₂ has a convex side surface 431 extending from a top of the top portion T₂ to a top of the bottom portion B₂, and has the first top width w₂₁ greater than the second top width w₂₂ of the bottom portion B₂.

FIG. 5 is a flowchart of a method 500 of fabricating a semiconductor structure in accordance with some exemplary embodiments of the instant disclosure. Operation 501 of the method is forming at least one top hole in a substrate. The method continues with operation 503 in which a bottom hole extending from a bottom of the top hole into the substrate is formed to form a hole. Operation 505, a dopant is introduced into a conductive region defined by the hole to form a conductive doped region. The method continues with operation 507 in which a dielectric material is filled in the hole. The method continues with operation 509 in which semiconductor devices are formed in the substrate. The method continues with operation 511 in which a top inter-layer dielectric (ILD) layer, top contact vias, a top metal layer are formed. Operation 513, the substrate is thinned from the bottom surface of the substrate. The method continues with operation 515 in which a bottom ILD layer, a bottom contact via, and a bottom metal layer are formed. Operation 517, the top metal layer and the bottom metal layer are patterned. It is understood that FIG. 5 has been simplified for a good understanding of the concepts of the instant disclosure. Accordingly, it should be noted that additional processes may be provided before, during, and after the methods of FIG. 5, and that some other processes may only be briefly described herein.

FIGS. 6A to 6I are cross-sectional views of a method for manufacturing a semiconductor structure 600 at various stages in accordance with some embodiments of the instant disclosure. FIG. 7 is a top view of the substrate shown in FIG. 6A.

Reference is made to FIGS. 6A and 7. At least one top hole H₃₁ is formed in a substrate 601 (operation 501 of FIG. 5). The top hole H₃₁ is a ring hole. The substrate 601 shown in FIG. 6A is a cross-sectional view of FIG. 7 along the line AA′. As shown in FIG. 6A, the top hole H₃₁ has two cross sections. As shown in FIG. 7, the top hole H₃₁ is rectangular ring-shaped. However, it is noted that the scope of this application is not limited thereto. In some other embodiments, the top hole H₃₁ is circular ring-shaped, polygonal ring-shaped, or irregular ring-shaped.

In some embodiments, the substrate 601 is a wafer substrate. The wafer substrate may be a silicon wafer, silicon-germanium wafer, germanium wafer, or gallium-arsenide wafer. The substrate 601 may be a lightly doped (P− or N−), moderately doped (P or N), highly doped (P+ or N+), or heavily doped (P++ or N++) wafer.

Still referring to FIG. 6A, a patterned mask layer 603 which has an opening 605 is formed on the substrate 601. An etching process, e.g., an isotropic etching process, by using the patterned mask layer 603 as an etch mask, can remove a portion of the substrate 601 to form the top hole H₃₁. The top hole H₃₁ is a blind hole. In some embodiments, the isotropic etching process is a wet etching process.

As shown in FIG. 6A, the top hole H₃₁ has a width decreases from top to bottom. In other words, the top hole H₃₁ tapers from the top surface S₃₁ of the substrate 601 toward the bottom surface S₃₂ of the substrate 601. In some embodiments, the top hole H₃₁ is formed by etching the substrate 601 through the opening 605 by an isotropic etching process. Accordingly, the top hole H₃₁ is concave. Both of the two cross sections of the top hole H₃₁ are similar to a cross section of a bowl, as shown in FIG. 6A. An inner surface 607 of the top hole H₃₁ is concave, and a side surface 607 a of the inner surface 607 of the top hole H₃₁ is also concave. It is noted that the scope of this application is not limited thereto. The shape of the top hole H₃₁ can be adjusted by using another etching process. In some other embodiments, both of the two cross sections of the top hole H₃₁ are substantially inverted trapezoidal, and the side surface of the top hole H₃₁ is substantially straight. In still some other embodiments, the top hole H₃₁ has a convex side surface.

Please refer to FIGS. 6A and 7 again. A conductive region 609 defined by the top hole H₃₁ is in the substrate 601. As shown in FIG. 7, the conductive region 609 is surrounded by the top hole H₃₁. Because the top hole H₃₁ shown in FIG. 7 is rectangular ring-shaped, the conductive region 609 is rectangular in the top view. However, it is noted that the scope of this application is not limited thereto. In some other embodiments, the shape of the conductive region 609 is circular, polygonal, or irregular in the top view.

Reference is made to FIG. 6B. A bottom hole H₃₂ extending from a bottom of the top hole H₃₁ into the substrate 601 is formed to form a hole H₃ (the operation 503 of FIG. 5). In other words, forming the bottom hole H₃₂ stops before the bottom hole H₃₂ penetrates through the substrate 601. The bottom hole H₃₂ is a ring hole. The top hole H₃₁ in communication with the bottom hole H₃₂ is referred to as a top hole H_(31a). Because both the top hole H_(31a) and the bottom hole H₃₂ are ring-shaped, the hole H₃ is also a ring hole. Two cross sections of the hole H₃ are shown in FIG. 6B. An etching process, e.g., an anisotropic etching process, by using the patterned mask layer 603 as an etch mask, can remove a portion of the substrate 601 to form the bottom hole H₃₂. In some embodiments, the anisotropic etching process is dry etching process, e.g., DRIE. For example, DRIE is Bosch etching or cryogenic etching. After forming the hole H₃, the patterned mask layer 603 is removed.

In some embodiments, the bottom hole H₃₂ is formed by etching the substrate 601 through the opening 605 by an anisotropic etching process. Accordingly, a side surface 611 a of an inner surface 611 of the bottom hole H₃₂ is substantially straight. In some embodiments, the side surface 611 a of the bottom hole H₃₂ substantially aligns with a side surface 605 a of the opening 605 of the patterned mask layer 603. It is noted that the side surface 607 a of the top hole H_(31a) and the side surface 611 a of the bottom hole H₃₂ form an obtuse angle θ₃ as shown in FIG. 6B.

Still referring to FIG. 6B, the top hole H_(31a) has a first top width w₃₁ and a first height h₃₁. In some embodiments, the ratio of the first height h₃₁ to the first top width w₃₁ is about 0.5 to about 2. In some embodiments, the first top width w₃₁ ranges from about 0.2 to about 15 μm. In some embodiments, the first height h₃₁ ranges from about 0.1 to about 10 μm. The bottom hole H₃₂ has a second top width w₃₂ and a second height h₃₂. The second height h₃₂ is greater than the first height h₃₁. In some embodiments, the ratio of the second height h₃₂ to the second top width w₃₂ is about 1 to about 20. In some embodiments, the second top width w₃₂ ranges from about 0.1 to about 10 μm. In some embodiments, the second height h₃₂ ranges from about 1 to about 200 μm.

As shown in FIG. 6B, the first top width w₃₁ of the top hole H_(31a) is greater than the second top width w₃₂ of the bottom hole H₃₂, and thus the upper portion (i.e., the top hole H_(31a)) of the hole H₃ is wider than the lower portion (i.e., the bottom hole H₃₂) of the hole H₃. Such shape of the hole H₃ is good for filling material, such as conductive material and dielectric material, into the hole H₃ without causing seams or voids in the material. During the filling process, the material can be deposited on the inner surface of the hole H₃ to fill the hole H₃, such that the material filled in the hole H₃ has a smooth and planar top surface.

Reference is made to FIG. 6C. A dopant is introduced into the conductive region 609 defined by the hole H₃ to form a conductive doped region 609 a (operation 505 of FIG. 5). The dopant, depending on which type the substrate 601 is, may be phosphorus, arsenic, boron, aluminum, gallium, or combinations thereof. The dopant may be doped by ion implanting or diffusion.

Attention is now invited to FIG. 6D. A dielectric material 613 is filled in the hole H₃ (operation 507 of FIG. 5). In some embodiments, the dielectric material 613 is referred to as a filler. Accordingly, the operation 507 also can be regarded as forming a filler in the top hole H_(31a) and the bottom hole H₃₂. More specifically, the dielectric material 613 is conformally disposed in the top hole H_(31a) and the bottom hole H₃₂ and in contact with the inner surface 607 of the top hole H_(31a) and the inner surface 611 of the bottom hole H₃₂. Because the hole H₃ is ring-shaped, the dielectric material 613 disposed in the hole H₃ is a ring in shape. Because the top hole H_(31a) is wider than the bottom hole h₃₂, the hole H₃ can be filled with the dielectric material 613. Moreover, there can be no seam or void in the dielectric material 613, and the dielectric material 613 has a substantially planar top surface. In other words, the dielectric material 613 can be seam-free and void-free.

The dielectric material 613 may include an oxide or nitride material. The dielectric material 613 is formed by deposition methods including thermal oxidation, low-pressure chemical vapor deposition (LPCVD), atmospheric-pressure chemical vapor deposition (APCVD), plasma-enhanced chemical vapor deposition (PECVD) and future-developed deposition procedures. In some embodiments, the deposition process includes a chemical mechanical polishing (CMP) process to remove the dielectric material 613 on the top surface S₃₁ of the substrate 601.

Please refer to FIG. 6E. Semiconductor devices 615 are formed in the substrate 601 (operation 509 of FIG. 5). Because the dielectric material 613 and conductive doped region 609 a are formed before forming the semiconductor devices 615, the method of fabricating the semiconductor structure in the instant disclosure is a front-end-of-line (FEOL) process. The semiconductor devices 615 may include transistors, capacitors, resistors, or combinations thereof. The semiconductor devices 615, for example, are complementary metal-oxide semiconductors (CMOS). The operation of forming the semiconductor devices may include depositing, pattering, etching, doping, and any other operation known in the art.

Turning now to FIG. 6F, a top inter-layer dielectric (ILD) layer 617, top contact vias 619, and a top metal layer 621 are formed (the operation 511 of FIG. 5). In other words, an interconnection structure 623 including the top ILD layer 617, the top contact vias 619, and the top metal layer 621 is formed. Because the operation 511 is performed after forming the semiconductor devices 615, the operation 511 and the subsequent operations are back end of line (BEOL) process.

Still referring to FIG. 6F, the top ILD layer 617 is formed over the top surface S₃₁ of the substrate 601; the top contact vias 619 are formed in the top ILD layer 617; and the top metal layer 621 is formed over the top ILD layer 617. The top ILD layer 617 may include a low-K dielectric material, such as phosphosilicate glass (PSG), borophosphosilicate glass (BPSG), fluorinated silicate glass (FSG), SiO_(x)C_(y), spin-on-glass, spin-on-polymers, silicon carbon material, silicon oxide, silicon nitride, and combinations thereof. The top ILD layer 617 is formed by suitable method known in the art, such as spinning, CVD, PECVD, or LPCVD. The top contact vias 619 and the top metal layer 621 are electrically connected to the conductive doped region 609 a and the semiconductor devices 615. In some embodiments, the top contact vias 619 and the top metal layer 621 are formed by etching part of the top ILD layer 617 and depositing a copper-based or aluminum-based material. For example, the copper-based material include substantially pure elemental copper, copper containing unavoidable impurities, and copper alloys containing minor amounts of elements such as tantalum, indium, tin, zinc, manganese, chromium, titanium, germanium, strontium, platinum, magnesium, aluminum or zirconium. In some embodiments, a protection layer 625 is formed over the top metal layer 621 for protecting the interconnection structure 623. The protection layer 625 may include silicon oxide and silicon nitride and is formed by deposition method such as CVD, PVD, or sputtering.

Attention is now invited to FIG. 6G. The substrate 601 is thinned from the bottom surface S₃₂ of the substrate 601 (the operation 513 of FIG. 5). Accordingly, the dielectric material 613 is exposed and a conductive pillar 609 b is formed. The substrate 601 may be thinned by a grinding, etching, and/or polishing process to isolate the conductive doped region 609 a to form the conductive pillar 609 b. The conductive pillar 609 b is surrounded by the dielectric material 613, which is filled in the hole H₃, and is isolated to the substrate 601. The conductive pillar 609 b has a top portion 609 b ₁ and a bottom portion 609 b ₂, and the top portion 609 b ₁ of the conductive pillar 609 b gets wider toward the bottom portion 609 b ₂ of the conductive pillar 609 b. It is noted that after operation 513, the shape of the bottom hole H₃₂ is changed, and the shape of the hole H₃ is changed accordingly. The changed bottom hole H₃₂ is referred to as a bottom hole H_(32a) which has a second height h_(32a) shorter than the second height h₃₂ of the bottom hole H₃₂. The changed hole H₃ is referred to as a hole H_(3a).

Please refer to FIG. 6H. A bottom ILD layer 627, a bottom contact via 629, and a bottom metal layer 631 are formed (the operation 515 of FIG. 5). In other words, an interconnection structure 633 including the bottom ILD layer 627, the bottom contact via 629, and the bottom metal layer 631 is formed. The bottom ILD layer 627 is formed over the bottom surface S₃₂ of the substrate 601; the bottom contact via 629 is formed in the bottom ILD layer 627; the bottom metal layer 631 covers the bottom ILD layer 627. The bottom ILD layer 627 may include the same material with the top ILD layer 617, for example, silicon oxide or BPSG. The bottom ILD layer 627 may be formed by suitable method known in the art, such as spinning, PVD, CVD, PECVD, or LPCVD. The bottom contact via 629 and the bottom metal layer 631 are electrically connected to the conductive pillar 609 b. The bottom contact via 629 and the bottom metal layer 631 are formed by etching part of the bottom ILD layer 627 and depositing a conductive material, such as the copper-based material or aluminum-based material.

Please refer to FIG. 6I. The top metal layer 621 and the bottom metal layer 631 are patterned to form a top metal layer 621 a and bottom metal layer 631 a (the operation 517 of FIG. 5). Accordingly, the semiconductor structure 600 is formed.

As shown in FIG. 6I, the semiconductor structure 600 includes the substrate 601, the conductive pillar 609 b, the dielectric material 613, the semiconductor devices 615, the interconnection structure 623, and the interconnection structure 633. The interconnection structure 623 includes the top ILD layer 617, the top contact vias 619, and the top metal layer 621 a. The interconnection structure 633 includes the bottom ILD layer 627, the bottom contact via 629, and the bottom metal layer 631 a. The substrate 601 has the top surface S₃₁ and the bottom surface S₃₂, and has the hole H_(3a) therein. The hole H_(3a) is a ring hole, and extends through the substrate 601 between the top surface S₃₁ and the bottom surface S₃₂. The hole H_(3a) has two cross sections as shown in FIG. 6I. The two cross sections are funnel-shaped. The hole H_(3a) has the top hole H_(31a) and the bottom hole H_(32a) under the top hole H_(31a). The top hole H_(31a) and the bottom hole H_(32a) are in communication with each other. The side surface 607 a of the top hole H_(31a) and the side surface 611 a of the bottom hole H_(32a) form the obtuse angle θ₃. The top hole H_(31a) has the first top width w₃₁ greater than the second top width w₃₂ of the bottom hole H_(32a). Moreover, the top hole H_(31a) tapers from the top surface S₃₁ toward the bottom hole H_(32a) (or the bottom surface S₃₂). In some embodiments, the side surface 607 a of the top hole H_(31a) is curved. In FIG. 6I, the side surface 607 a of the top hole H_(31a) is concave. In some other embodiments, the side surface of the top hole H_(31a) is convex or substantially straight. The dielectric material 613 is conformally disposed and filled in the top hole H_(31a) and the bottom hole H_(32a), and in contact with the inner surface 607 of the top hole H_(31a) and the inner surface 611 of the bottom hole H_(32a). Because the hole H_(3a) is ring-shaped, the dielectric material 613 disposed in the hole H₃ is a ring in shape. Accordingly, the conductive pillar 609 b is surrounded by the dielectric material 613. The conductive pillar 609 b is in the substrate 601, and has the top portion 609 b ₁ and the bottom portion 609 b ₂. The top portion 609 b ₁ of the conductive pillar 609 b gets wider toward the bottom portion 609 b ₂ of the conductive pillar 609 b. It is noted that both the dielectric material 613 and the conductive pillar 609 b penetrates through the substrate 601. The interconnection structure 623 is disposed on the top surface S₃₁ of the substrate 601. More specifically, the top ILD layer 617 and the top contact vias 619 are disposed on the top surface S₃₁. The top contact vias 619 are in contact with the conductive pillar 609 b and the semiconductor devices 615. The top metal layer 621 a is in contact with the top contact vias 619. The interconnection structure 633 is disposed on the bottom surface S₃₂ of the substrate 601. More specifically, the bottom ILD layer 627 and the bottom contact via 629 are disposed on the bottom surface S₃₂. The bottom contact via 629 is in contact with the conductive pillar 609 b. The bottom metal layer 631 a is in contact with the bottom contact via 629. The top contact vias 619 and the top metal layer 621 a are electrically connected to the bottom contact via 629 and the bottom metal layer 631 a through the conductive pillar 609 b.

Still referring to FIG. 6I, as previously described, in some embodiments, the dielectric material 613 is referred to as a filler. Therefore, alternatively, the semiconductor structure 600 includes a filler F₃ disposed in the top hole H_(31a) and the bottom hole H_(32a). The filler F₃ includes a top portion T₃ (i.e., the portion of the dielectric material 613 filled in the top hole H_(11a)) and a bottom portion B₃ (i.e., the portion of the dielectric material 613 filled in the bottom hole H_(12a)) in contact with the top portion T₃. As shown in FIG. 6I, the top portion T₃ has a convex side surface 635 extending from a top of the top portion T₃ to a top of the bottom portion B₃, and has the first top width w₃₁ greater than the second top width w₃₂ of the bottom portion B₃.

FIG. 8 is a flowchart of a method 800 of fabricating a semiconductor structure in accordance with some embodiments of the instant disclosure. Operation 801 of the method is receiving a carrier, a bottom electrode embedded in the carrier, and an insulating film on the carrier. The method continues with operation 803 in which a top electrode is formed on the insulating film to form a cavity between the carrier, the insulating film, and the top electrode. Operation 805, a top hole is formed in the top electrode. The method continues with operation 807 in which a bottom hole extending from a bottom of the top hole into the top electrode is formed to form a funnel-shaped through hole. The method continues with operation 809 in which a sealing material is formed in the funnel-shaped through hole. The method continues with operation 811 in which a cap is formed on the top electrode. It is understood that FIG. 8 has been simplified for a good understanding of the concepts of the instant disclosure. Accordingly, it should be noted that additional processes may be provided before, during, and after the methods of FIG. 8, and that some other processes may only be briefly described herein.

FIGS. 9A to 9F are cross-sectional views of a method for manufacturing a semiconductor structure 900 at various stages in accordance with some embodiments of the instant disclosure.

Reference is made to FIG. 9A. A carrier 901, a bottom electrode 903 embedded in the carrier 901, and an insulating film 905 on the carrier 901 are received (the operation 801 of FIG. 8). The carrier 901 has a recess 907, which is surrounded by the insulating film 905. In some embodiments, the carrier 901 is a semiconductor substrate. Examples of semiconductors include silicon, silicon on insulator (SOI), Ge, SiC, GaAs, GaAlAs, InP, and GaNSiGe. The carrier 901 may be doped of either n-type or p-type, or undoped. In some embodiments, metal oxide semiconductor field effect transistors (MOSFETs) are added to the carrier 901. These can be of the n-type, the p-type or both types in a complementary metal oxide semiconductor (CMOS) process. In some embodiments, a CMOS device is embedded in the carrier 901. The bottom electrode 903 may be electrically connected with the CMOS device. In some other embodiments, a portion of the CMOS device is the bottom electrode 903.

Reference is made to FIG. 9B. A top electrode 909 is formed on the insulating film 905 to form a cavity 911 between the carrier 901, the insulating film 905, and the top electrode 909 (operation 803 of FIG. 8). In some embodiments, the top electrode 909 is referred to as a substrate, and the substrate is conductive. The cavity 911 is isolated from the surroundings. That is, the cavity 911 is enclosed. Moreover, the top electrode 909 is isolated from the bottom electrode 903 by the carrier 901 and the insulating film 905. Accordingly, the carrier 901, the bottom electrode 903, the insulating film 905, and the top electrode 909 form a capacitor CP. The capacitance between the top electrode 909 and the bottom electrode 903 is determined by the distance between them.

The top electrode 909 may be made of suitable conductive material. Examples of the conductive material include but not limited to polycrystalline silicon, molybdenum (Mo), aluminum (Al), titanium (Ti), tantalum (Ta), copper (Cu), tin (Sn), nickel (Ni), gold (Au), silver (Ag), tungsten (W), chromium (Cr), platinum (Pt), metal alloy, or combinations thereof. In some embodiments, the polycrystalline silicon is doped with impurities.

Reference is made to FIG. 9C. A top hole H₄₁ is formed in the top electrode 909 (the operation 805 of FIG. 8). More specifically, a patterned mask layer 913 which has an opening 915 is formed on the top electrode 909. An etching process, e.g., an isotropic etching process, by using the patterned mask layer 913 as an etch mask, can remove a portion of the top electrode 909 to form the top hole H₄₁. The top hole H₄₁ is a blind hole. In some embodiments, the isotropic etching process is a wet etching process.

The top hole H₄₁ has a width decreases from top to bottom. In other words, the top hole H₄₁ tapers from the top surface S₄₁ of the top electrode 909 toward the bottom surface S₄₂ of the top electrode 909. In some embodiments, the top hole H₄₁ is formed by etching the top electrode 909 through the opening 915 by an isotropic etching process. Accordingly, the top hole H₄₁ is substantially bowl-shaped. In other words, the top hole H₄₁ is concave. Accordingly, an inner surface 917 of the top hole H₄₁ is concave, and a side surface 917 a of the inner surface 917 of the top hole H₄₁ is also concave. It is noted that the scope of this application is not limited thereto. The shape of the top hole H₄₁ can be adjusted by using another etching process. In some other embodiments, the cross section of the top hole H₄₁ is substantially inverted trapezoidal, and the side surface of the top hole H₄₁ is substantially straight. In still some other embodiments, the top hole H₄₁ has a convex side surface.

Attention is now invited to FIG. 9D. A bottom hole H₄₂ extending from a bottom of the top hole H₄₁ into the top electrode 909 is formed to form a funnel-shaped through hole H₄ (the operation 807 of FIG. 8). In other words, forming the bottom hole H₄₂ stops until the bottom hole H₄₂ penetrates through the top electrode 909. The top hole H₄₁ in communication with the bottom hole H₄₂ is referred to as a top hole H_(41a). An etching process, e.g., an anisotropic etching process, by using the patterned mask layer 913 as an etch mask, can remove a portion of the top electrode 909 to form the bottom hole H₄₂. In some embodiments, the anisotropic etching process is dry etching process, e.g., deep reactive-ion etching (DRIE). For example, DRIE is Bosch etching or cryogenic etching.

In some embodiments, the bottom hole H₄₂ is formed by etching the top electrode 909 through the opening 915 by an anisotropic etching process. Because the anisotropic etching etches in a single direction into the surface of the top electrode 909, as shown in FIG. 9D, the bottom hole H₄₂ is a substantially straight hole. In some embodiments, an inner surface 919 (i.e., a side surface 919 a) of the bottom hole H₄₂ is substantially straight. In some embodiments, the inner surface 919 (i.e., the side surface 919 a) of the bottom hole H₄₂ substantially aligns with a side surface 915 a of the opening 915 of the patterned mask layer 913. It is noted that the side surface 917 a of the top hole H_(41a) and the side surface 919 a of the bottom hole H₄₂ form an obtuse angle θ₄ as shown in FIG. 9D. After forming the funnel-shaped through hole H₄, the patterned mask layer 913 is removed.

At this stage, the cavity 911 is in communication with the surroundings via the funnel-shaped through hole H₄, and therefore the pressure of the cavity 911 is substantially equal to the pressure of the surroundings. In some embodiments, the funnel-shaped through hole H₄ is referred to as a vent hole.

Still referring to FIG. 9D, the top hole H_(41a) has a first top width w₄₁ and a first height h₄₁. In some embodiments, the ratio of the first height h₄₁ to the first top width w₄₁ is about 0.5 to about 2. In some embodiments, the first top width w₄₁ ranges from about 0.2 to about 15 μm. In some embodiments, the first height h₄₁ ranges from about 0.1 to about 10 μm. The bottom hole H₄₂ has a second top width w₄₂ and a second height h₄₂. The second height h₄₂ is greater than the first height h₄₁. In some embodiments, the second top width w₄₂ ranges from about 0.1 to about 10 μm.

As shown in FIG. 9D, the first top width w₄₁ of the top hole H_(41a) is greater than the second top width w₄₂ of the bottom hole H₄₂, and thus the upper portion (i.e., the top hole H_(41a)) of the funnel-shaped through hole H₄ is wider than the lower portion (i.e., bottom hole H₄₂) of the funnel-shaped through hole H₄. Such shape of the funnel-shaped through hole H₄ is good for forming sealing material, such as conductive material and dielectric material, to seal the funnel-shaped through hole H₄ without causing seams or voids in the sealing material. Moreover, the sealing material filled in the funnel-shaped through hole H₄ has a smooth and planar top surface.

Please refer to FIG. 9E. A sealing material 921 is formed in the funnel-shaped through hole H₄ to seal the funnel-shaped through hole H₄ (the operation 809 of FIG. 8). In some embodiments, the sealing material 921 is referred to as a filler. Accordingly, the operation 809 also can be regarded as forming a filler in the top hole H_(41a) and the bottom hole H₄₂. The sealing material 921 is conformally disposed in the top hole H_(41a) and the bottom hole H₄₂, and in contact with the inner surface 917 of the top hole H_(41a) and the inner surface 919 of the bottom hole H₄₂. At this stage, the cavity 911 is isolated from the surroundings again by the sealing material 921. That is, the cavity 911 is an enclosed cavity. In FIG. 9E, the sealing material 921 covers a portion of the top surface S₄₁ of the top electrode 909. However, it is noted that the scope of this application is not limited thereto. In some other embodiments, the sealing material 921 is disposed in the funnel-shaped through hole H₄ but without covering the top surface S₄₁. In FIG. 9E, the sealing material 921 covers the side surface 917 a of the top hole H_(41a) and a portion of the side surface 919 a of the bottom hole H₄₂, and an air gap 911 a is formed in the bottom hole H₄₂ of the funnel-shaped through hole H₄ and under the sealing material 921. However, it is noted that the scope of this application is not limited thereto. In some other embodiments, the funnel-shaped through hole H₄ is filled with the sealing material 921. In still some other embodiments, a portion of the sealing material 921 protrudes from the lower surface S₄₂ of the top electrode 909.

Because the top hole H_(41a) is wider than the bottom hole h₄₂, the funnel-shaped through hole H₄ can be sealed with the sealing material 921. Moreover, there can be no seam or void in the sealing material 921, and the sealing material 921 has a substantially planar top surface. In other words, the sealing material 921 can be seam-free and void-free. Accordingly, the problem that the funnel-shaped through hole H₄ is not entirely sealed by the sealing material 921 can be avoided.

The sealing material 921 is conductive or non-conductive. Accordingly, the sealing material 921 may be made of suitable dielectric material or conductive material. Examples of the dielectric material include but not limited to silicon oxide (SiO₂), silicon nitride (Si₃N₄), silicon oxynitride (SiO_(x)N_(y)), aluminum oxide (Al₂O₃), aluminum nitride (AlN), aluminum oxynitride (AlON) or a combination thereof. Examples of the conductive material include but not limited to molybdenum (Mo), aluminum (Al), titanium (Ti), tantalum (Ta), copper (Cu), tin (Sn), nickel (Ni), gold (Au), silver (Ag), tungsten (W), chromium (Cr), platinum (Pt), metal alloy, or a combination thereof.

It is noted that, before forming the sealing material 921, the pressure of the cavity 911 is same as the pressure of the surroundings. After forming the sealing material 921 to isolate the cavity 911 from the surroundings, when the pressure of the surroundings changes, the cavity 911 would expand or compress. Accordingly, the distance between the top electrode 909 and the bottom electrode 903 would be changed, and the capacitance between the top electrode 909 and the bottom electrode 903 would be changed accordingly. By measuring the capacitance, the pressure difference between the cavity 911 and the surroundings can be detected. Accordingly, the whole structure shown in FIG. 9E can be used to detect ambient pressure. In some embodiments, the whole structure shown in FIG. 9E is referred to as a capacitive pressure sensor.

Turning now to FIG. 9F, a cap 923 is formed on the top electrode 909 for protecting the structure shown in FIG. 9E (the operation 811 of FIG. 8). The cap 110 is bonded with the top electrode 909 by using suitable processes, such as eutectic bonding, thermal compression bonding and adhesive bonding. An enclosed cavity 925 is defined by the top electrode 909, the sealing material 921, and the cap 923. Accordingly, the semiconductor structure 900 is formed.

As shown in FIG. 9F, the semiconductor structure 900 includes the capacitor CP, the sealing material 921, and the cap 923. The capacitor CP includes the carrier 901, the bottom electrode 903, the insulating film 905, and the top electrode 909. The top electrode 909 has the top surface S₄₁ and the bottom surface S₄₂, and has the funnel-shaped through hole H₄ therein. The funnel-shaped through hole H₄ extends through the top electrode 909 between the top surface S₄₁ and the bottom surface S₄₂. The funnel-shaped through hole H₄ has the top hole H_(41a) and the bottom hole H₄₂ under the top hole H_(41a). The top hole H_(41a) and the bottom hole H₄₂ are in communication with each other. The side surface 917 a of the top hole H_(41a) and the side surface 919 a of the bottom hole H₄₂ form the obtuse angle θ₄. The top hole H_(41a) has the first top width w₄₁ greater than the second top width w₄₂ of the bottom hole H₄₂. Moreover, the top hole H_(41a) tapers from the top surface S₄₁ toward the bottom hole H₄₂ (or the bottom surface S₄₂). In some embodiments, the side surface 917 a of the top hole H_(41a) is curved. In FIG. 9F, the side surface 917 a of the top hole H_(41a) is concave. In some other embodiments, the side surface of the top hole H_(41a) is convex or substantially straight. The sealing material 921 is conformally disposed in the top hole H_(41a) and the bottom hole H₄₂ and in contact with the inner surface 917 of the top hole H_(41a) and the inner surface 919 of the bottom hole H₄₂ to seal the top hole H_(41a) and the bottom hole H₄₂. In FIG. 9F, the sealing material 921 covers the side surface 917 a of the top hole H_(41a) and a portion of the side surface 919 a of the bottom hole H₄₂. However, it is noted that the scope of this application is not limited thereto. In some other embodiments, the funnel-shaped through hole H₄ is filled with the sealing material 921. In still some other embodiments, a portion of the sealing material 921 protrudes from the lower surface S₄₂ of the top electrode 909. Further, in FIG. 9F, the sealing material 921 covers the top surface S₄₁ of the top electrode 909. However, it is noted that the scope of this application is not limited thereto. In some other embodiments, the sealing material 921 does not cover the top surface S₄₁ of the top electrode 909. The carrier 901 is disposed under the top electrode 909. The lower electrode 903 is embedded in the carrier 901. The insulating film 905 is disposed between the top electrode 909 and the carrier 901, wherein the cavity 911 is defined by the carrier 901, the insulating film 905, and the top electrode 909. In some embodiments, the top electrode 909 is referred to as a substrate, and the substrate is conductive.

Still referring to FIG. 9F, as previously described, in some embodiments, the sealing material 921 is referred to as a filler. Therefore, alternatively, the semiconductor structure 900 includes a filler F₄ disposed in the top hole H_(41a) and the bottom hole H₄₂. The filler F₄ includes a top portion T₄ (i.e., the portion of the sealing material 921 filled in the top hole H_(41a)) and a bottom portion B₄ (i.e., the portion of the sealing material 921 filled in the bottom hole H₄₂) in contact with the top portion T₄. As shown in FIG. 9F, the top portion T₄ has a convex side surface 927 extending from a top of the top portion T₄ to a top of the bottom portion B₄, and has the first top width w₄₁ greater than the second top width w₄₂ of the bottom portion B₄.

From the above descriptions, both the funnel-shaped blind hole and the funnel-shaped through hole are good for filling material and forming sealing material into these holes and reducing the possibility of causing seams or voids within these materials. Accordingly, during fabrication of semiconductor structures, problems caused by seams or voids can be avoided.

In some embodiments of the instant disclosure, a semiconductor structure includes a substrate, a hole which includes a top hole and a bottom hole in communication with each other in the substrate, and a filler in the top hole and the bottom hole, wherein the top hole tapers toward the bottom hole, and a side surface of the top hole and a side surface of the bottom hole form an obtuse angle.

In some embodiments of the instant disclosure, a semiconductor structure includes a substrate having a funnel-shaped hole therein, and a filler disposed in the funnel-shaped hole, wherein the filler comprises a top portion and a bottom portion in contact with the top portion, the top portion has a convex side surface extending from a top of the top portion to a top of the bottom portion, and has a first top width greater than a second top width of the bottom portion.

In some embodiments of the instant disclosure, a method of fabricating a semiconductor structure includes the following steps. A top hole extending from a top surface of a substrate into the substrate and tapering toward a bottom surface of the substrate is formed, wherein the top hole is concave. A bottom hole extending from a bottom of the top hole into the substrate is formed. A filler is formed in the top hole and the bottom hole.

The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure. 

What is claimed is:
 1. A semiconductor structure, comprising: a substrate; a hole in the substrate and comprising a top hole and a bottom hole in communication with each other, wherein the top hole tapers toward the bottom hole, and a side surface of the top hole and a side surface of the bottom hole form an obtuse angle; and a filler disposed in the top hole and the bottom hole.
 2. The semiconductor structure of claim 1, wherein the side surface of the top hole is curved.
 3. The semiconductor structure of claim 1, wherein the side surface of the bottom hole is substantially straight.
 4. The semiconductor structure of claim 1, wherein the top hole has a first height, the bottom hole has a second height, and the second height is greater than the first height.
 5. The semiconductor structure of claim 1, wherein the filler comprises a dielectric material in contact with inner surfaces of the top hole and the bottom hole.
 6. The semiconductor structure of claim 5, wherein the dielectric material is conformally disposed in the top hole and the bottom hole, and the filler further comprises a conductive material disposed on the dielectric material and in the top hole and the bottom hole.
 7. The semiconductor structure of claim 5, wherein the dielectric material is conformally disposed in the top hole and the bottom hole, and the filler further comprises: a bottom electrode conformally disposed on the dielectric material and at least partially in the top hole and the bottom hole; a dielectric interlayer conformally disposed on the bottom electrode and at least partially in the top hole and the bottom hole; and a top electrode disposed on the dielectric interlayer.
 8. The semiconductor structure of claim 7, wherein the substrate comprises a doped region, and the top hole and the bottom hole are disposed in the doped region.
 9. The semiconductor structure of claim 5, wherein the top hole is a ring hole, the bottom hole is a ring hole, and the dielectric material disposed in the top hole and the bottom hole is a ring in shape.
 10. The semiconductor structure of claim 9, further comprising a conductive pillar in the substrate and surrounded by the dielectric material, wherein the conductive pillar has a top portion and a bottom portion, and the top portion of the conductive pillar gets wider toward the bottom portion of the conductive pillar.
 11. The semiconductor structure of claim 1, further comprising: a carrier disposed under the substrate, and an electrode embedded in the carrier; and an insulating film disposed between the substrate and the carrier, wherein an enclosed cavity is defined by the carrier, the insulating film, and the substrate, and the substrate is conductive.
 12. A semiconductor structure, comprising: a substrate having a funnel-shaped hole therein; and a filler disposed in the funnel-shaped hole, wherein the filler comprises a top portion and a bottom portion in contact with the top portion, the top portion has a convex side surface extending from a top of the top portion to a top of the bottom portion, and has a first top width greater than a second top width of the bottom portion.
 13. The semiconductor structure of claim 12, wherein the filler is conductive.
 14. The semiconductor structure of claim 12, wherein the substrate is conductive.
 15. The semiconductor structure of claim 12, wherein an air gap is formed in the funnel-shaped hole and under the filler.
 16. A method of fabricating a semiconductor structure, comprising: forming a top hole extending from a top surface of a substrate into the substrate and tapering toward a bottom surface of the substrate, wherein the top hole is concave; forming a bottom hole extending from a bottom of the top hole into the substrate; and forming a filler in the top hole and the bottom hole.
 17. The method of claim 16, wherein forming the top hole and the bottom hole comprises: forming a patterned mask layer having an opening on the top surface of the substrate; etching the substrate through the opening by an isotropic etching to form the top hole; and etching the substrate through the opening by an anisotropic etching to form the bottom hole.
 18. The method of claim 16, wherein forming the bottom hole extending from the bottom of the top hole into the substrate stops before the bottom hole penetrates through the substrate.
 19. The method of claim 18, further comprising thinning the substrate from the bottom surface of the substrate to expose the filler.
 20. The method of claim 16, wherein forming the bottom hole extending from the bottom of the top hole into the substrate stops until the bottom hole penetrates through the substrate. 